Battery system with temperature sensors

ABSTRACT

A battery system includes a platform having an aperture formed therethrough, a flexible member having a generally planar configuration and extending across the aperture, wherein a portion of the flexible member is coextensive with the aperture, a cell provided adjacent the platform, and a sensor coupled to the flexible member and positioned proximate the cell. The sensor is configured to detect a temperature of the cell.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.12/084,060, filed on Apr. 24, 2008, as a national phase application ofInternational Application PCT/U.S. 2006/039288, filed Oct. 6, 2006,which in turn claims the benefit of and priority to U.S. ProvisionalPatent Application No. 60/730,908, filed Oct. 27, 2005. The entiredisclosures of U.S. patent application Ser. No. 12/084,060,International Application PCT/U.S. 2006/039288, and U.S. ProvisionalPatent Application No. 60/730,908 are incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

The government of the United States has rights in this inventionpursuant to Contract No. DE-FC26-95EE50425 awarded by the U.S.Department of Energy.

BACKGROUND

The present inventions relate to batteries (e.g., lithium-ion batteries,lithium-polymer batteries, nickel-metal hydride (NiMH) batteries, etc.)and systems using such batteries. More specifically, the presentinventions relate to battery systems that utilize one or moretemperature sensors to measure or detect the temperature of cells withinthe battery system.

It is known to provide batteries for use in vehicles such asautomobiles. For example, lead-acid batteries have been used instarting, lighting, and ignition applications. More recently, hybridvehicles have been produced which utilize a battery (e.g., anickel-metal-hydride battery) in combination with other systems (e.g.,an internal combustion engine) to provide power for the vehicle.

It is generally known that lithium batteries (e.g., lithium-ionbatteries, lithium-polymer batteries, etc.) perform differently thannickel-metal-hydride batteries. In some applications, it may bedesirable to obtain the enhanced power/performance of a lithium battery.For example, lithium batteries may provide greater specific power thannickel-metal-hydride batteries. However, the application of lithiumbattery technology may present design and engineering challenges beyondthose typically presented in the application of conventionalnickel-metal-hydride battery technology.

The design and management of a lithium battery system that can beadvantageously utilized in a hybrid vehicle may involve considerationssuch as electrical performance monitoring, thermal management, andcontainment of effluent (e.g., gases that may be vented from a batterycell).

Current methods of thermal management include providing a temperaturesensor on a battery module. The sensors are attached to the module usingadditional parts and clips and are exposed to ambient temperaturegradients which may affect performance and accuracy of the measuredtemperature.

It would be advantageous to provide an improved system for monitoringtemperature in a lithium battery module. It would also be advantageousto provide a system for monitoring temperature that is relatively simpleand economical, and which may be relatively easily assembled. It wouldbe desirable to provide a system including any one or more of these orother advantageous features as may be apparent to those reviewing thepresent disclosure.

SUMMARY

According to an exemplary embodiment, a battery system includes aplatform having an aperture formed therethrough, a flexible memberhaving a generally planar configuration and extending across theaperture, wherein a portion of the flexible member is coextensive withthe aperture, a cell provided adjacent the platform, and a sensorcoupled to the flexible member and positioned proximate the cell. Thesensor is configured to detect a temperature of the cell.

According to another exemplary embodiment, a battery system includes aplatform, a cell supported by the platform and having a bottom end, aflexible member positioned beneath the bottom end of the cell, and asensor coupled to the flexible member and positioned proximate thebottom end of the cell. The sensor is configured to detect a temperatureof the cell.

According to another exemplary embodiment, a battery system includes aplatform including a top surface, a plurality of apertures extendingthrough the top surface, and a plurality of cells supported by theplatform, each of the plurality of cells aligned with one of theplurality of apertures. The battery system also includes a plurality oftemperature sensors, each of the plurality of sensors provided proximatean end of one of the plurality of cells and aligned with the associatedaperture. The battery system further includes a plurality of flexiblemembers, each of the flexible members positioned beneath an end of oneof the plurality of cells and having a generally planar configurationthat extends across the associated aperture. The flexible members areconfigured to support the associated sensor to allow movement of theassociated sensor while maintaining it proximate the associated cell.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a battery system or module that includesa plurality of battery cells according to an exemplary embodiment.

FIG. 2 is a perspective view of a portion of the battery system ormodule shown in FIG. 1.

FIG. 3 is a perspective view of a battery tray according to an exemplaryembodiment.

FIG. 4 is a perspective view of a portion of a battery system or modulethat includes a temperature sensing device according to an exemplaryembodiment.

FIG. 5 is a cross-sectional view of a portion of the portion of thebattery system shown in FIG. 4.

FIG. 6 is another perspective view showing the portion of the batterysystem shown in FIG. 4.

FIG. 7 is a cutaway plan view of a battery system or module having atemperature sensing device according to an exemplary embodiment.

FIG. 8 is a cutaway plan view of a battery system or module having atemperature sensing device according to an exemplary embodiment.

DETAILED DESCRIPTION

According to an exemplary embodiment, a battery system or module isprovided that includes a plurality of batteries or cells (e.g.,lithium-ion cells, lithium-polymer cells, NiMH cells, etc.). It shouldbe noted that while particular exemplary embodiments are shown anddescribed in the present application for the cells and modules, featuresdescribed herein may be utilized with cells of any presently knownconfiguration or other configuration that may be developed in thefuture.

Various nonexclusive exemplary embodiments of lithium batteries andlithium battery systems are shown and described in U.S. patentapplication Ser. No. 10/976,169, filed Oct. 28, 2004, and inInternational Application No. PCT/U.S. 2005/030244 filed Aug. 25, 2005,the entire disclosures of which are hereby incorporated by reference.The batteries, modules, and other features described herein, includingthe temperature sensors and related devices, may be used in conjunctionwith features disclosed in U.S. patent application Ser. No. 10/976,169and/or International Application No. PCT/U.S. 2005/030244, as will beappreciated by those of skill in the art reviewing this disclosure.

While FIGS. 1-8 illustrate particular exemplary embodiments of batteriesand battery systems, any of a variety of batteries or battery systemsmay be used according to various exemplary embodiments. For example,according to various exemplary embodiments, the physical configurationof the individual cells and/or the modules may be varied according todesign objectives and considerations (e.g., cells having a generallyoval cross-sectional shape, cells having a generally cylindrical shape,and cells having a generally prismatic shape).

Features of exemplary batteries or cells that may be used with batterysystems or modules such as those shown and described herein aredescribed in detail below. It should be understood by those reviewingthis disclosure that similar or identical features may be included incells according to any of the embodiments shown herein. According toother exemplary embodiments, additional and/or different features may beprovided for cells used in such embodiments.

According to an exemplary embodiment, a cell (e.g., cell 150 as shown inFIG. 1) includes a container and a cover (which may be referred toand/or be provided in the form of, for example, as an end cover, collar,cap, top portion, end portion, etc.) for sealing the cells. According tovarious exemplary embodiments, the cover may be made from any suitablematerial (e.g., metals, plastics, composites, etc.). The containers ofthe cells may have any of a variety of shapes, sizes, andconfigurations. For example, a container may be octagonal, cylindrical,generally flattened-oval, octal-oval, prismatic, or any of a variety ofother shapes.

Within the cell containers, the cells include electrodes (e.g., positiveand negative electrodes) and separators that are wound or wrapped suchthat they have a generally oval or elliptical shape (or other shape,depending on the shape of the container used) to form a cell element. Anelement or strap may be coupled to the one or more electrodes of asingle polarity type (e.g., the positive electrode(s) or the negativeelectrode(s)) and to the associated terminals to couple the associatedelectrode(s) and terminals and to gather or collect current and/or heatfrom within a cell).

Terminals are provided for electrically coupling to cells to each otherand to the vehicle electrical system, and are coupled to the straps.According to an exemplary embodiment, each cell includes two positiveand two negative terminals. According to other exemplary embodiments, adifferent number of positive and negative terminals may be provided foreach cell.

Each cell may also include one or more vents for allowing effluent(e.g., gas, liquid, and/or other materials) to escape (e.g., to beexhausted or expressed from) the interior of the cell. The vent may be avalve such as relief or burst valve to permit effluent to escape thecell. An aperture may be in fluid communication with the interior of thecell. When the cell is in its normal operating mode, the aperture isblocked by some element. In the event that effluent builds up to apredetermined threshold, the element may move to expose the aperturesuch that effluent may escape the cell. According to an exemplaryembodiment, a vent may be configured to allow gas and/or other materialsto escape from the cell when the pressure within the cell reaches aparticular threshold (e.g., a high pressure threshold of betweenapproximately 3 psi and 30 psi).

A plurality of cells electrically coupled together may be arranged in amodule, such as that shown in U.S. patent application Ser. No.10/976,169 (e.g., having channels for airflow and effluent removal,etc.), for use with the present invention.

The number of cells provided within a particular module may varyaccording to various exemplary embodiments. Further, it should be notedthat battery systems may include any number of modules which include anynumber of batteries (e.g., three modules may be provided within abattery system, each of which may include any suitable number of cells).The particular configuration utilized for a battery system and/or modulemay be optimized to provide power for a particular application accordingto various exemplary embodiments.

According to an exemplary embodiment, a module may have a voltage ofbetween approximately 40 and 48 volts and that is rated at 12 amp hoursand which includes 12 cells. The dimensions of such a module may beapproximately 95 mm wide by 143 mm tall by 421 mm long, with a weight ofapproximately 7 kg. According to various other exemplary embodiments,the dimensions, ratings, or other characteristics may differ accordingto any of a variety of desired characteristics.

FIGS. 1-2 illustrate a battery module 100 according to an exemplaryembodiment that includes a plurality of battery cells 150 (e.g.prismatic, oval, or cylindrical cells). The module 100 includes amanifold or cooling system 110 configured to provide a cooling fluid(e.g., air) that passes over at least a portion (e.g., the terminals) ofthe cells 150 of the module 100 in parallel fashion (e.g., a cover 102having channels provided therein may be utilized). That is, the coolingfluid is routed such that it does not pass over all cells 150 of themodule 100 (which would accumulate heat as the air passed from one cellto the next), but rather, is instead routed such that it passes overonly one or two of the cells 150. The fluid (e.g., air) flow isrepresented by lines 120, 152, and 153 shown in FIG. 2. According to anexemplary embodiment shown in FIG. 2, the cooling fluid (shown in line152) passes downward along cell 150 (e.g., across the terminals and downalong the housing of the cell), after which it is exhausted at a memberor base 130 of module 100 (shown by line 153). While FIGS. 1-2illustrate a battery module having a manifold system for providing acooling fluid adjacent cells of the module, according to other exemplaryembodiments, a different manifold system or no manifold system isprovided

According to an exemplary embodiment, a battery system or module mayinclude one or more members or devices for monitoring, sensing,detecting, or determining the temperature of one or more cells includedin the battery system or module. FIGS. 3-8 illustrate exemplaryembodiments in which a temperature sensing member or device 242 (e.g., atemperature sensor) is provided adjacent or in contact with at least oneof the cells 150 of a battery module 100 for individually sensing thetemperature of the cells 150. It should be noted that such temperaturesensors may be provided in any of the exemplary embodiments shown inthis disclosure, including embodiments that utilize oval, cylindrical,and prismatic cells. For simplicity, similar elements are numbered withidentical reference numerals even though their configuration may not beidentical.

FIG. 3 illustrates a perspective view of the underside of a member orbase 230 (e.g., a battery tray) of a battery system or module accordingto an exemplary embodiment. Member 230 is similar to member 130 shown inFIGS. 1-2 in that the member 230 includes a plurality of features orplatforms 232 on which batteries or cells 250 may rest (see, e.g., FIG.4, showing a cell 250 arranged or provided on a feature or platform232).

According to an exemplary embodiment, one or more wires 240 (FIG. 4) areprovided such that they extend through an aperture or hole formed in aportion of the base 230. According to an exemplary embodiment shown inFIGS. 4-6, the wires 240 extend through an aperture or hole 234 formedin a feature 236 (e.g., a spacer or extension that extends intointerstitial space between adjacent cells in the battery system ormodule) provided as part of the base 230. The feature 236 is provided inrelatively close proximity to the platform 232 and, accordingly, to acell which may be provided on the platform 232.

A member or device 242 for measuring or determining temperature (e.g., atemperature sensor) is electrically coupled to the wire 240. Accordingto an exemplary embodiment, the device 242 is provided on the platform232 such that it is provided proximate or in contact with a cell (e.g.,cell 250) that is provided on the platform 232. Any suitable type oftemperature sensor may be utilized according to various exemplaryembodiments (e.g., the sensor may include a thermistor, a thermocouple,etc.).

FIGS. 4-6 illustrates placement of the device 242 according to anexemplary embodiment. The platform 232 includes an aperture or hole 233provided in the top surface thereof. The device 242 is provided abovethe aperture 233 and rests on a flexible member 244 such as a diaphragm.One advantageous feature of providing a flexible member 244 is that thetemperature sensor may be maintained in close proximity of the bottom ofa cell 250 that is provided on the platform 232 with an appropriatelevel of force. For example, when placed on the platform 232, the cellmay force the device 242 downward through the aperture 233. The flexiblemember 244 allows for movement of the device 242 while maintaining closeproximity between the device 242 and the cell 250 (e.g., the flexiblemember 244 may be made of a relatively resilient material). FIG. 6illustrates a portion of the underside of the base 230 illustrating theflexible member 244 in position adjacent the aperture 233.

A member or element 246 such as a gasket or washer (e.g., a ring-likestructure or member) is provided above the flexible member 244 accordingto an exemplary embodiment. According to an exemplary embodiment, themember 246 surrounds the device 242 to provide a relatively isolatedenvironment in which the device 242 may operate (e.g., a cooling fluidsuch as air flowing by the cells may not pass over the device 242, whichallows for more accurate temperature sensing for the cell). By providinggasket 246, the need to encapsulate the temperature sensor with an epoxyor other material may be eliminated, as it keeps the temperature sensorwithin the proximity of the cell.

The one or more wires 240 extending from the device 242 may be coupledto a system (e.g., a battery management system, a vehicle communicationsystem such as a vehicle bus, etc). The system may act to control thetemperature of the module and/or individual cells within the modulebased at least in part on information transmitted from the device 242.For example, in the event that the temperature of a cell or a moduleexceeds a predetermined threshold, the module may be disconnected fromthe vehicle power system according to an exemplary embodiment. Accordingto another exemplary embodiment, individual cells may be disconnectedfrom the vehicle power system. Other actions may also be taken accordingto other exemplary embodiments (e.g., routing additional cooling fluidto a particular cell, decreasing the amount of power provided by aparticular cell, etc.) that are intended to manage the temperature ofindividual cells in the module.

FIG. 7 shows a battery module 200 having a plurality of cells 250provided within a housing 202. A member or base 230 of the module 200includes a plurality of features or platforms 232 on which the cells 250are placed. A member or device 242 (e.g., a temperature sensor) ismaintained in contact with a bottom surface of a cell 250 by a flexiblemember 244 such as a diaphragm and the force from the cell 250 held inplace above the member 244 by the housing 202. It should be noted thatwhile FIG. 7 illustrates only one device 242, any number of similardevices may be used. For example, one such device may be provided foreach of the platforms (i.e., for each of the cells in the module).

FIG. 8 illustrates the use of a member or device 342 similar to thedevice 242 utilized in a battery system or module 300 having a pluralityof generally prismatic cells 350. The cells 350 are provided between afirst (e.g., top) cover 320 and a second (e.g., bottom) cover 330. Amember or element 331 in the form of a plate or panel is provided tosecure or clamp the first and second covers and cells together as abattery pack. An aperture or hole 333 is provided in the second cover330, and the device 342 having one or more wires 340 coupled thereto isprovided on a flexible member 344 provided between the second cover 330and the member 331. A depression or cutout 337 is provided in the member331 into which the device 342 and the flexible member 344 may extendwhen provided in contact with the cell 350. As shown in FIG. 8, theflexible member 344 constrains movement of the device 342 whilemaintaining it in close contact with a portion of the cell 350. As withthe other exemplary embodiments shown and described herein, any numberof devices 342 may be provided in the module 300 (e.g., one for eachcell, etc.).

The flexible members (e.g., flexible members 244 and 344) may beprovided as a single piece of adhesive-backed neoprene (or othersuitable material) in the form of a diaphragm according to an exemplaryembodiment. The adhesive may act to secure the flexible member to thetemperature sensor. According to other exemplary embodiments, theflexible member does not include an adhesive for securing the member toa temperature sensor.

It should be understood by those reviewing this disclosure thattemperature sensors may be provided as shown herein in a variety ofdifferent modules, including modules that utilize oval-shaped cells,prismatic cells, cylindrical cells, or other types of cells. Forexample, the cells shown having a generally oval shape may be providedin a module along with one or more temperature sensors that are held incontact with a surface of the cells by a flexible member such as adiaphragm.

It would be desirable to provide a battery system of a type disclosed inthe present application that includes a battery system that includes oneor more battery cells (e.g., lithium-ion cells, NiMH cells, etc.) forproviding power to a vehicle. It would also be desirable to provide abattery system that includes a system for monitoring the temperature ofa battery cell. Furthermore, it may be advantageous to provide a batterysystem that includes features for maintaining temperature sensors incontact with cells in the battery system.

Various advantages may be obtained by providing temperature sensors orthe like in contact with batteries or cells using a flexible member suchas a diaphragm. For example, battery modules using such a configurationmay be assembled and disassembled relatively simply, and may use fewercomponents as compared to other battery modules having differenttemperature sensing configurations and devices. For example, nofasteners are required to secure the temperature sensor in position.

Another advantageous feature of the temperature sensor arrangement isthat the mounting method maintains a relatively consistent andappropriate (e.g., not excessive) force holding the sensor to the cellwhile allowing for some dimensional variation of the components.Furthermore, an appropriate amount of holding force may reduce oreliminate damage to the sensors.

It is important to note that the construction and arrangement of thesystems and structures shown in the various exemplary embodiments areillustrative only. Although only a few embodiments have been describedin detail in this disclosure, those skilled in the art who review thisdisclosure will readily appreciate that many modifications are possible(e.g., variations in sizes, dimensions, structures, shapes andproportions of the various elements, values of parameters, mountingarrangements, use of materials, colors, orientations, etc.) withoutmaterially departing from the novel teachings and advantages of thesubject matter recited in the claims. For example, elements shown asintegrally formed may be constructed of multiple parts or elements, theposition of elements may be reversed or otherwise, and the nature ornumber of discrete elements or positions may be altered or varied.Accordingly, all such modifications are intended to be included withinthe scope of the present invention as defined in the appended claims.The order or sequence of any process or method steps may be varied orre-sequenced according to alternative embodiments. Other substitutions,modifications, changes and omissions may be made in the design,operating conditions and arrangement of the various exemplaryembodiments without departing from the scope of the present inventions.

1. A battery system comprising: a platform having an aperture formedtherethrough; a flexible member having a generally planar configurationand extending across the aperture; a cell provided adjacent theplatform; and a sensor coupled to the flexible member and positionedproximate the cell, the sensor configured to detect a temperature of thecell.
 2. The battery system of claim 1, wherein the flexible member is aseparate component that is distinct from the platform.
 3. The batterysystem of claim 1, wherein the sensor is aligned with the aperture. 4.The battery system of claim 1, further comprising an isolating membersurrounding the sensor and positioned between the cell and the platform.5. The battery system of claim 1, wherein the flexible member isconfigured to allow movement of the sensor relative to the aperturewhile maintaining the sensor proximate the cell.
 6. The battery systemof claim 1, wherein the sensor is positioned on a surface of theflexible member above the aperture.
 7. The battery system of claim 6,wherein the sensor is coupled to the flexible member by an adhesivematerial.
 8. The battery system of claim 1, further comprising a systemfor monitoring the temperature of the cell.
 9. The battery system ofclaim 1, wherein the battery system comprises a plurality of cells, andeach of a plurality of the cells is positioned adjacent a sensor that iscoupled to a flexible member.
 10. A battery system, comprising: aplatform; a cell supported by the platform and having a bottom end; aflexible member positioned beneath the bottom end of the cell; and asensor coupled to the flexible member and positioned proximate thebottom end of the cell; wherein the sensor is configured to detect atemperature of the cell.
 11. The battery system of claim 10, wherein theflexible member is a separate component that is distinct from theplatform.
 12. The battery system of claim 10, further comprising anisolating member surrounding the sensor and positioned between the celland the platform.
 13. The battery system of claim 10, wherein theflexible member is configured to allow movement of the sensor whilemaintaining the sensor proximate the cell.
 14. The battery system ofclaim 10, wherein the platform includes an aperture formed therethroughand the flexible member extends across the aperture to cover theaperture.
 15. The battery system of claim 10, wherein the sensor isaligned within the aperture.
 16. The battery system of claim 10, furthercomprising a system for monitoring the temperature of the cell.
 17. Abattery system, comprising: a platform including a top surface; aplurality of apertures extending through the top surface; a plurality ofcells supported by the platform, each of the plurality of cells alignedwith one of the plurality of apertures; a plurality of temperaturesensors, each of the plurality of sensors provided proximate an end ofone of the plurality of cells and aligned with the associated aperture;a plurality of flexible members, each of the flexible members positionedbeneath an end of one of the plurality of cells and having a generallyplanar configuration that extends across the associated aperture; andwherein the flexible members are configured to support the associatedsensor to allow movement of the associated sensor while maintaining itproximate the associated cell.
 18. The battery system of claim 17,wherein each of the flexible members is a separate component that isdistinct from the platform.
 19. The battery system of claim 17, furthercomprising a plurality of isolating members, each of the isolatingmembers surrounding a sensor and positioned between the associated celland the platform.
 20. The battery system of claim 17, further comprisinga system for monitoring the temperatures of the plurality of cells.